Chemical Safety Audit Checklist For Plants, Labs And Warehouses
Summary
Use this practical chemical safety audit checklist to walk your plant, lab or warehouse, verify storage and labeling, review PPE and SDSs, and close gaps before customer or regulatory inspections.
Practical, regulation aligned checklists for supervisors and EHS leads who actually walk the floor, written by a bulk chemical supplier that runs its own warehouses, drum lines, and quality labs every day.
Who this guide is for
This article is written for operations managers, EHS coordinators, quality leaders, maintenance supervisors, and anyone who owns chemical safety in a plant, warehouse, lab, or blending facility. If you store drums, totes, railcars, cylinders, or lab packs, sign hazardous waste manifests, or answer questions from auditors, this checklist is designed for you.
Alliance Chemical operates and supplies real working facilities, so the examples here come from daily practice: forklift traffic, pallet racks, day tanks, hose reels, vapor clouds that were prevented, and a lot of lessons learned from near misses. The goal is a simple inspection pattern that supports OSHA, NFPA, and EPA requirements without overwhelming your team.
Most chemical incidents are preventable and they usually start with the same small problems: unlabeled secondary containers, expired or missing SDS sheets, blocked emergency equipment, unknown hose runs, and waste drums that no one really owns. A short, repeatable checklist that you actually use every week usually does more for safety and compliance than a thick binder of policies that nobody reads.
Below you will find a seven part chemical safety checklist you can plug into your inspections, an area by area inspection table, and example products that make it easier to standardize labeling, PPE, and storage. The structure is compatible with common requirements in OSHA Hazard Communication (29 CFR 1910.1200), flammable liquids rules, local fire code expectations, and typical customer and registrar audits.
A bulk chemical warehouse with palletized materials staged so inspectors can see labels, aisles, and containment.
Why chemical safety audits matter more than ever
Chemical safety is not only about avoiding fines. It affects uptime, insurance, employee morale, product quality, and your ability to win new business. Many of the plants and labs Alliance Chemical supplies are audited several times a year by customers, registrars, corporate EHS, and regulators. The sites that consistently pass inspections are usually the ones that treat chemical control as a routine operations task, not a one time compliance project.
The questions inspectors ask are remarkably consistent, whether they are from OSHA, a customer, or an ISO auditor.
- Regulators look for evidence that you know what chemicals are on site, where they are stored, and how you control exposure. They expect a written program, but they also look hard at the floor conditions in front of them.
- Insurers care about loss history and whether you have real controls in place around flammables, corrosives, oxidizers, and toxics. Adjusters pay attention to segregation, housekeeping, ignition sources, and secondary containment.
- Customers and registrars look for clean, organized storage and clear documentation when they visit your site. Many are required to verify that their own supply chain handles chemicals responsibly.
- Employees decide whether they trust leadership based on how seriously you treat their exposure to chemicals. Sloppy storage and poor PPE control send a strong signal that safety is negotiable.
A working chemical safety audit connects these expectations to daily practice. In most facilities, the critical gaps show up in the same clusters: inventory and segregation, container condition and labeling, storage conditions, transfer and mixing, PPE and exposure control, spill response and waste, and finally documentation and follow up. That is how this guide is organized.
| Risk area | What can go wrong | Checklist focus |
|---|---|---|
| Storage and segregation | Incompatible chemicals stored together, heat sources near flammables, valves and shutoffs blocked by pallets. | Segregation rules, clear labels, distance from ignition sources, secured cylinders and totes, posted maximum quantities. |
| Labeling and documentation | Unlabeled containers, obsolete names in process sheets, SDS that do not match products or CAS numbers on site. | GHS labels on all containers, SDS availability, consistent product names and codes between paperwork and storage. |
| Transfer and dispensing | Hose failures, overfills, ungrounded transfers, improvised funnels and open containers that create vapor exposure. | Approved transfer procedures, hose and pump condition, grounding and bonding, drip control, closed transfer where possible. |
| PPE and exposure control | Incorrect glove materials, missing eye and face protection, respirator use without fit testing or cartridge change schedules. | Task specific PPE, signage at point of use, documented respiratory programs where required, eyewash and shower coverage. |
| Spill response and waste | Spills that spread through drains, incompatible wastes mixed together, containers left open, legacy drums no one claims. | Spill kits sized for nearby containers, neutralizers, waste labeling, written instructions by area, trained responders on each shift. |
Many findings start at a desk, when someone compares what is on the screen with what is actually on the floor.
What Alliance Chemical brings to your safety program
Alliance Chemical is more than a drum on a pallet with a packing slip. The technical team that wrote this checklist works every day with the same types of risks our customers manage. We operate warehouses with flammable and corrosive storage, run drum lines and small pack filling equipment, and maintain our own quality labs and documentation systems. The advice in this article is grounded in that experience.
- We supply solvents, acids, glycols, water treatment products, and specialty blends with SDS and Certificates of Analysis that match the exact product and lot you have on site.
- Product naming is kept consistent so that labels, purchase orders, work instructions, and inventory records use the same terminology, including CAS numbers and concentration descriptions.
- We stock multiple container sizes from quarts and gallons to drums and totes, which makes it easier to right size storage, reduce partial drums, and move high hazard work into smaller controlled packs.
- Our technical support group helps with compatibility questions, storage and temperature guidance, typical use ranges, and practical answers for auditors who ask about purity, inhibition packages, and product specifications.
If you need help mapping what is on your floor to a documented chemical list, our team can use your Alliance Chemical purchase history as a starting point for your hazardous materials inventory.
The seven part chemical safety checklist
Use the checklist below as a template for your own chemical safety audit. You can paste these items into your existing inspection form, EHS software, or digital checklist tool. Each step is framed so that a supervisor or lead can walk the floor and answer with yes, no, or follow up required. Treat it as a how to guide for your internal walkthrough.
1. Chemical inventory and segregation
Objective: know what is on site, where it is, and whether incompatible materials are separated in a way that matches your written program and local fire code expectations.
- A master chemical list exists and is current. Trade names, generic names, and chemical names are linked, including CAS number and supplier.
- Storage locations in the list match actual shelves, cages, rooms, and outdoor areas. If a drum moves, someone updates the location.
- Acids, caustics, oxidizers, flammables, and water reactives are separated and clearly identified on racking or cabinets. NFPA diamond or similar signage is visible.
- Maximum intended quantities are defined for each area so slow creep does not overload a room or violate control area limits.
- Obvious incompatibilities, such as oxidizers next to organics or acids next to cyanide solutions, are checked specifically in every audit.
2. Container condition and labeling
Objective: every container gives a clear, accurate picture of what is inside and is in good condition so there are no surprises during a leak, transfer, or emergency response.
- Manufacturer labels on drums, pails, and totes are present, readable, and match your inventory records and SDS titles.
- Secondary containers, including squeeze bottles, carboys, buckets, and day tanks, have workplace labels that identify the product and show the relevant hazard pictograms.
- No rusted, bulging, or leaking drums or pails are present in storage or at point of use. Any container with questionable integrity is tagged and removed from service.
- Old names or codes that no longer appear on SDS have been removed from labels and paperwork, so operators are not forced to translate between legacy terms and current documents.
- For private label or in house blends, the label template and SDS are controlled documents and they are updated together when a formulation changes.
3. Storage conditions and housekeeping
Objective: store chemicals so they are stable, contained, protected from damage, and easy to inspect. Good housekeeping sends a strong signal to auditors and employees that safety is taken seriously.
- Flammable liquids such as isopropyl alcohol, acetone, and heptane are stored in approved cabinets or rooms with ventilation and separation that aligns with NFPA and fire marshal expectations.
- Corrosives are on compatible shelving with intact secondary containment, splash protection, and clear separation between acids and caustics.
- Aisles, exits, electrical panels, and emergency equipment are accessible and not blocked by pallets, hoses, or temporary staging.
- Outdoor storage has clear labels, intact containment for totes and drums, rainwater and contaminated liquids are removed appropriately, and weather protection is present where needed.
- Housekeeping expectations are written down. The audit checks that those expectations are met rather than leaving conditions to individual opinion.
4. Transfer, dispensing, and mixing
Objective: control how chemicals move so small mistakes do not turn into large incidents. This is often where near misses happen, especially around temporary hoses and open transfers.
- Hoses, pumps, valves, and fittings used to move products like glycols, acids, caustics, and solvents are in good condition and rated for the service. There is a schedule for inspection and replacement.
- Grounding and bonding are in place where flammable liquids are dispensed, including drum pumps, day tanks, and mixing kettles.
- Fill lines, sight gauges, and level markings are accurate and used to avoid overfills. Alarms or interlocks, if present, are tested.
- Temporary setups such as flex hoses routed across walkways are documented, inspected, and removed when the job is done. Your checklist calls these out specifically.
- Mixing instructions, including order of addition, dilution limits, and neutralization procedures, are written and available at point of use so operators do not rely only on memory.
5. PPE and exposure controls
Objective: make sure people handling chemicals have the protection the SDS requires and know how to use it. The best programs use PPE, engineering controls, and work practices together rather than relying entirely on one layer.
- Glove selection matches the chemicals handled, using manufacturer resistance charts instead of a generic one size fits all approach. For example, the gloves used for concentrated sulfuric acid or sodium hydroxide are validated rather than assumed.
- Safety eyewear and face shields are available at transfer and mixing points. Eye protection is treated as required equipment, not a suggestion.
- Respiratory protection, if needed, has written procedures, documented medical clearance, and fit testing records in line with your respirator program.
- Visible signage in each area reminds people what PPE is required for that task. Your audit checks both that the signs exist and that people are actually following them.
- Local exhaust, general ventilation, and closed transfer options are evaluated periodically so that you are not relying on PPE for hazards that could be controlled at the source.
6. Spill response, neutralization, and waste
Objective: be ready for spills and manage waste in a way that avoids surprise liabilities and aligns with hazardous waste and water quality regulations.
- Spill kits are stocked, sealed, and sized correctly for the largest container nearby. Contents match the chemicals stored in that zone.
- Neutralizers or compatible absorbents are available for acids, caustics, and solvents. People know which products are suitable for which types of spills.
- Waste containers are labeled with contents and hazard phrase, not only generic terms such as waste solvent. Accumulation start dates are visible where required.
- Temporary waste accumulation points, satellite containers, and used PPE drums are identified on your map and are part of your inspection route.
- Emergency contact information, including internal numbers and any external response partners, is posted in spill prone areas and is consistent with your written plan.
7. Documentation, training, and follow up
Objective: prove that your system works over time, not only on audit day. A simple record system that is actually used is better than a complex one that no one trusts.
- SDS access is clearly posted and people know how to get to it during a real incident. This can be a physical binder or a digital system, but it must be available if the network is down.
- Training records show who is qualified to handle specific high hazard chemicals and to operate equipment such as drum pumps, tote stations, and neutralization systems.
- Inspection findings are logged with dates, responsible person, and closure dates. The log is reviewed periodically by operations leadership and EHS.
- Recurring issues trigger changes in procedure, engineering controls, or purchasing decisions rather than being written up the same way month after month.
- When auditors visit, you can show how your checklist fits into your overall program, including your written hazard communication plan, emergency response plan, and waste handling procedures.
High hazard transfers demand clear procedures, correct PPE, and equipment that is sized and rated for the job.
An area by area inspection table you can reuse
The table below converts the checklist into concrete questions by area. Many Alliance Chemical customers copy this structure into their monthly inspection forms or EHS software, then adapt it to match their process layout and terminology.
| Area | Inspection questions | Suggested frequency | Proof that it is under control |
|---|---|---|---|
| Main chemical warehouse | Are all pallets labeled with product name and hazard class Are flammable, corrosive, and oxidizing materials separated and identified Are any drums leaking, bulging, without bungs, or stacked in an unstable way |
Weekly | Inspection log, photos of corrected pallets, work orders for damaged drums, notes on segregation or containment improvements. |
| Drum and tote transfer area | Are pumps, hoses, and transfer lines free of cracks and visible damage Is grounding and bonding in place during solvent and fuel alcohol transfer Are drip pans, absorbents, and neutralizers present and not saturated |
Daily in use, weekly documented | Operator checklist, hose replacement records, test records for grounding clamps, photos of clean floors and sumps. |
| Lab and small pack room | Are all benchtop bottles labeled with product name and hazard pictogram Are acids and bases stored in separate cabinets or clearly separated shelves Is eyewash and safety shower accessible, tested, and documented |
Weekly | Test tags on eyewash and showers, label examples, records of cabinet inspections, log of corrective actions for clutter or unlabeled containers. |
| Outdoor storage and tank farm | Is secondary containment free of rainwater, debris, or accumulated product Are tank labels visible from access roads and emergency approach routes Are level indicators and overfill protection systems working and tested |
Weekly visual, annual functional testing | Photos of containment, test records, alarm test logs, work orders for valve repairs or containment cleaning. |
| Waste accumulation area | Are all waste drums labeled with contents and hazard phrase Are incompatible wastes not stored together Are dates and accumulation limits tracked, with a clear plan for pickups |
Weekly | Waste log, manifests, inspection checklist, photos of properly closed and labeled drums, notes from any regulatory inspections. |
Even simple looking liquids carry specific hazards. Inventory, SDS, and labels should make that clear.
Relevant chemicals and supplies to support your checklist
Standardizing core chemicals and pack sizes makes labeling, training, and inspection much easier. The products below are common Alliance Chemical items that show up repeatedly in plants and labs. Treat them as anchor points when you design storage, PPE, and transfer rules.
Isopropyl alcohol portfolio
High purity alcohol is one of the most common flammable liquids in labs and production areas. Standardizing on a defined range of grades and pack sizes simplifies storage, labeling, and PPE.
- Isopropyl Alcohol 70 percent USP for routine wipe downs and controlled disinfection applications.
- Isopropyl Alcohol 91 percent for electronics and parts cleaning where faster drying is helpful.
- Isopropyl Alcohol 99 percent for critical cleaning where low residue is important.
- Isopropyl Alcohol 99.9 percent ACS for analytical and high specification work in laboratories.
These grades are ideal reference points when you write flammable storage, PPE, and transfer procedures.
Deionized water
Deionized water is used for rinsing, solution preparation, and equipment cleaning. It looks harmless, but can carry contamination and contributes to corrosion and microbiological issues if systems leak or stagnate.
- Deionized Water in sizes from gallons to totes for process and laboratory use.
Include DI water storage and distribution in your inspections so piping changes, cross connections, and leaks are caught early.
Glycols for cooling systems
Closed loop cooling systems filled with inhibited glycols often hold thousands of pounds of liquid. They are easy to forget because they are not in drums, but they still create slip, environmental, and corrosion risks.
- Ethylene Glycol inhibited concentrates for industrial cooling loops and chillers.
- Propylene Glycol inhibited concentrates for systems where lower toxicity is preferred.
- Arctic Assist for applications that see extreme cold conditions.
Your checklist should include sight glasses, labeling, secondary containment, and leak inspection around these systems.
Corrosives such as acids and bases
Many facilities use mineral acids and caustic solutions for pH adjustment, cleaning in place systems, and process steps. These chemicals drive storage, PPE, and emergency shower requirements.
- Common examples include sulfuric, hydrochloric, and nitric acid blends in drums or totes for manufacturing and water treatment.
- Caustic soda solutions used for neutralization, cleaning, and process control.
Even if you source some corrosives from other suppliers, you can model segregation and PPE policies on how you handle your Alliance Chemical products.
High purity solvents and esters
Laboratory and production solvents influence fire risk, worker exposure, and environmental impact. Alliance Chemical supplies high purity grades used for cleaning, extraction, and formulation.
- Acetone ACS grade for laboratory use and controlled industrial cleaning.
- n Heptane 99 percent ACS for adhesive and oil removal in specific applications.
- Ethyl Acetate ACS grade and related esters for specialized cleaning and formulation work.
These products are useful anchors when you define flammable storage rooms, transfer controls, and ventilation requirements.
Small packs for bench top work
One of the fastest safety improvements in many facilities is to move high hazard activities from open pails and buckets into purpose sized, labeled small packs that match the job.
- Quarts and gallons of solvents and reagents for labs and pilot lines that currently draw from large drums.
- Five gallon pails that replace improvised buckets filled from drums in uncontrolled ways.
Ask the Alliance Chemical technical team about converting a portion of your drum volume into smaller pack sizes for safer daily handling.
Important note on product and checklist images
For this article you can reuse your existing Alliance Chemical pack shots for the products listed above and pair them with the operational images in this guide. Placing at least one real world image near each major section helps both search engines and human readers understand that your safety content is tied to actual practice in working facilities.
Frequently asked questions about chemical safety audits
Q: How often should we perform a chemical safety audit
A: At minimum, conduct a documented chemical safety walkthrough once per month that covers all storage, transfer, and waste areas. High turnover sites or operations with frequent process changes often move to a light weekly checklist for supervisors and a deeper monthly or quarterly audit led by EHS. Many Alliance Chemical customers also schedule an annual third party review as a second set of eyes.
Q: Who should own the checklist
A: Operations leadership should own the checklist, with EHS providing structure, training, and oversight. When audits are seen as something only the safety department does, findings take longer to fix. When supervisors run the checklist, maintenance and warehouse teams close items quickly, and EHS acts as a coach and resource instead of a separate police force.
Q: Can we use a single checklist for the entire site
A: You can start with one master checklist, especially if you are just beginning to formalize your program. Most sites eventually split it into a few focused versions: warehouse, production, lab, outdoor storage, and waste. The core logic stays the same, but the questions become sharper and more relevant to the people who walk that area every day.
Q: How does Alliance Chemical support audits and EHS programs
A: Our team routinely helps customers answer auditor questions about specific products, inhibition packages, purity, and typical use conditions. We provide SDS, Certificates of Analysis, product specifications, and practical storage guidance. Many customers route auditor questions about product chemistry and handling recommendations to us so they can focus on demonstrating their own procedures and records on site.
Q: What is an easy way to show improvement over time
A: Trend your findings by area and by type. For example, count how many issues each month relate to labeling, housekeeping, segregation, or transfer equipment. When you see that labeling problems have dropped while transfer issues are rising, you know where to focus your next round of training and engineering improvements. Simple charts built from your own checklist data are very effective with auditors and leadership.
About the author and how to get help
Next steps for your facility
- Copy the seven part checklist into your inspection form or EHS software and assign owners by area.
- Pick one or two high risk zones such as drum transfer or waste accumulation and run a focused audit using the table above.
- Standardize core chemicals such as isopropyl alcohol, glycols, and key acids to reduce variation in labeling and PPE decisions.
- Use a short monthly meeting to review findings, prioritize items that need capital or engineering support, and close out quick wins.
- Contact Alliance Chemical if you want help aligning your product list, SDS set, and storage plan with a documented checklist that you can show to auditors and customers.
